Cushioning device for footwear

ABSTRACT

A cushioning device for footwear that provides flexibility in the forepart area. The device having an insole with perforations in the forepart region and a first pad underlying the region. The device having a cutout in the heel region with an insert provided in the cutout.

This application is a 37.1 of PCT/AU99/00671 filed Aug. 20, 1999.

FIELD OF THE INVENTION

The present invention relates to a cushioning device for footwear,footwear incorporating such a cushioning device, a method of manufactureof a cushioning device and a method of manufacture of footwearincorporating such a cushioning device.

A pressure mapping study of the pressures that occur underfoot whilst awearer walks on a treadmill has indicated that there are large areas ofhigh pressure under the heel and under the forepart of the foot. Theseareas also contain points of peak pressure to which the wearer's foot issubjected during walking and running due to impact shock and stress.

BACKGROUND ART

Inserts for footwear which are intended to improve the wearer's comfortare known. However, these inserts are merely inserted into the footwear.Such inserts are not part of the manufactured footwear item but areadded later by the wearer. Other prior art devices provide cushioningsystems within the footwear itself, e.g. in the outsole.

Such prior art devices do not, however, specifically target the areas ofthe foot that are subject to high and peak pressure to provide effectivecushioning to the foot from a wide range of impacts.

The present invention is directed toward a cushioning device andfootwear which provides cushioning and energy impact absorption to theparts of the foot most susceptible to high and peak pressures due toimpact shock and stress forces.

In accordance with one aspect of the present invention there is provideda cushioning device for footwear comprising an insole;

a region at the forepart of said insole having perforations such thatsaid region at the forepart of said insole has greater flexibility thanthe remainder of said insole, to enable said region at the forepart ofsaid insole to conform in response to compression imparted to saidinsole;

first pad means on the under-face of said insole underlying said regionat the forepart of said insole, said first pad is of substantially thesame shape and size as said region at the forepart of said insole;

a cutout opening in the heel region of said insole;

an insert provided in said cutout opening;

second pad on the under-face of said insole underlying said insert; and

said first and second pad and said insert being substantially shockabsorbing and resilient.

In accordance with a second aspect of the present invention there isprovided an item of footwear comprising a footwear upper, a cushioningdevice as hereinbefore described, and an outsole attached to saidfootwear upper, wherein said outsole covers said first and second padmeans and said under-face of said insole.

In accordance with a third aspect of the present invention there isprovided a method of making a cushioning device for footwear comprising:

providing an insole;

perforating a region at the forepart of said insole such that saidregion at the forepart of said insole has greater flexibility than theremainder of said insole to enable said region at the forepart of saidinsole to conform in response to compression imparted to said insole;

underlying said region at the forepart of said insole with a first padon the under-face of said insole said first pad being substantially thesame shape and size as said region at the forepart of said insole;

cutting out an opening in the heel region of said insole;

positioning an insert in said opening;

underlying said insert with a second pad on the under-face of saidinsole; and

said first and second pad and said insert being substantially shockabsorbent and resilient.

In accordance with a fourth aspect of the present invention there isprovided a method of making an item of footwear comprising providing afootwear upper, providing a cushioning device as hereinbefore described,covering said first and second pad means and said under-face of saidinsole with an outsole, and attaching said outsole to said footwearupper.

Preferably, said region at the forepart of said insole substantiallycoincides with the first to fifth metatarsal heads and big toe of aperson's foot.

Preferably, cover means is provided over said first pad means at saidforepart of said insole.

Preferably, said first pad means is attached to said insole.

Preferably, said second pad means is attached to said insole and saidinsert means.

Preferably, shank support means is provided at substantially the midregion of said insole intermediate said forepart and said heel regionthereof.

Preferably, said shank support means does not overlap with said first orsecond pad means.

Preferably, said shank support means is substantially in the form of astrip of supportive material having greater rigidity than said insole.

Preferably, said shank support means is provided on said under-face ofsaid insole.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described, by way of example, withreference to the accompanying drawings, in which:

FIG. 1 is a plan view of the insole of an embodiment of a cushioningdevice in accordance with a first aspect of the present invention;

FIG. 2 is a plan view of a pad to underlie the forepart region of theinsole shown in FIG. 1;

FIG. 3 is a plan view of an insert for the cutout opening in the heelregion of the insole shown in FIG. 1;

FIG. 4 is a second pad to underlie the insert in the heel region of theinsole shown in FIG. 1;

FIG. 5 is a cover to cover the first pad at the forepart of the insoleshown in FIG. 1;

FIG. 6 is a cross-sectional view of an embodiment of an item of footwearin accordance with a second aspect of the present inventionincorporating an embodiment of a cushioning device in accordance withthe first aspect of the present invention;

FIG. 7 is a cross-sectional view taken along the lines 7—7 shown in FIG.6;

FIG. 8 is a cross-sectional view taken along the lines 8—8 shown in FIG.6; and

FIG. 9 is a cross-sectional view taken along the lines 9—9 shown in FIG.6.

BEST MODE(S) FOR CARRYING OUT THE INVENTION

In FIGS. 6-9 there is shown an item of footwear 100 incorporating acushioning device 10 for footwear.

The parts of the cushioning device 10, except the shank support 32, areshown separately in FIGS. 1-5. Thus, FIGS. 1-5 may be considered as anexploded view of the cushioning device 10 incorporated in the footwear100. The cushioning device 10 shown in FIGS. 1-5 is for a right footshoe.

For convenience of description, the cushioning device 10 of the presentinvention will be described with reference to FIGS. 1-5 and also FIGS.6-9.

The cushioning device 10 comprises an insole 12, a region 14 at theforepart 16 of the insole 12 which has greater flexibility than theremainder of the insole 12, a first pad 18 on the under-face 34 of theinsole 12 underlying the region 14 of the insole 12, a cutout opening 20in the heel region 22 of the insole 12, an insert 24 provided in the cutout opening 20 and a second pad 26 on the under-face 34 of the insole 12underlying the insert 24. The first and second pads 18 and 26 and theinsert 24 are substantially shock absorbing and resilient.

The region 14 that has greater flexibility than the remainder of theinsole 12 substantially coincides with the first to fifth metatarsalheads and big toe of a person's foot.

A cover 30 may be provided over the first pad 18.

The cover 30 assists in retaining the first pad 18 in place duringconstruction of an item of footwear 100 incorporating the cushioningdevice 10. The cover 30 may be adhered to the first pad 18 and theinsole 12, for example, with a contact adhesive.

In the embodiment shown in the drawings, the forepart 16 of the insole12 is provided with perforations 28. The perforations 28 thus form theregion 14 at the forepart 16 of the insole 12 that has greaterflexibility than the remainder of the insole 12.

The perforations 28 may be of any suitable dimension which providesincreased flexibility at the region 14 of the forepart 16 of the insole12. For example, the perforations may be approximately 1 mm-2 mm indiameter.

The first pad 18 is attached to the insole 12. This may be done, forexample, with a pressure sensitive adhesive.

The second pad 26 is attached to the insert 24 in the heel region 22 ofthe insole 12 and to the portion of the insole 12 surrounding the insert24. Thus, the second pad 26 is larger than the insert 24 such that itoverlaps onto the insole 12. This can be best seen in FIGS. 6 and 9. Thesecond pad 26 may be attached to the insert 24 and insole 12, forexample, by a hot-melt adhesive. The surfaces of the insert 24 and thesecond pad 26 may be scoured to enhance grip of the adhesive thereto.

A shank support 32 may be provided at the mid region 33 of the insole 12intermediate the forepart 16 and the heel region 22.

The shank support 32 is provided such that it does not overlap with thefirst or second pads 18 and 24.

The shank support 32 may be provided as a strip of supportive materialthat is more rigid than the material of the insole 12. For example, theshank support 32 may be made from polycarbonate, steel or nylon.

The shank support 32 may be attached to the insole 12 by adhesive,riveting or other suitable means.

The insole 12 has first and second faces 34 and 36, respectively. Thefirst face 34 is the under-face, or under-surface, of the insole 12. Thesecond face 36 is the upper face, or the upper surface, of the insole12.

The first and second pads 18 and 26, the cover 30 and the shank support32 are provided on the first face 34 of the insole 12.

The insole 12 is a single piece of material.

The insole 12 may be made of non-woven textile material or fibreboard.

FIGS. 6-9 show an embodiment of an item of footwear 100, in the form ofa shoe, incorporating a cushioning device 10. The item of footwear 100comprises a footwear upper 102, a cushioning device 10, and an outsole106 attached to the footwear upper 102. An innersock 103 is providedinside the item of footwear 100 and overlies the insole 12. The use ofsuch an innersock 103 is known in the art.

The footwear upper 102 is provided with a lasting margin 104. Thelasting margin 104 substantially surrounds the periphery of thecushioning device 10 and is attached to the cushioning device 10.

The first and second pads 18 and 26 of the cushioning device 10 and theshank support 32 are provided on the first face 34 of the insole 12 suchthat the outsole 106 covers the first and second pads 18 and 26, theshank support 32 and the first face 34 of the insole 12.

Thus, the first and second pads 18 and 26, the cover 30 and the shanksupport 32 are provided on the underside of the insole 12 when thecushioning device 10 is incorporated into an item of footwear 100.Accordingly, when incorporated in an item of footwear 100 it is thesecond face 36 of the insole 12 of the cushioning device 10 which facesa wearer's foot.

The first and second pads 18 and 26, the cover 30 and the shank support32 are embedded in the outsole 106 as shown in FIG. 6.

A method of making a cushioning device for footwear in accordance withthe present invention will now be described.

Insoles 12 may be cut from insole material. The insoles 12 are cut tothe required shoe size for a left and right shoe as required.

Markings may then be placed on the insole 12 to indicate the portion tobe cut out from the heel region 22 of the insole 12, the location of theregion 14 at the forepart 16 of the insole 12 and the location of theshank support 32 at the mid region 33 of the insole 12.

The region 14 at the forepart 16 of the insole 12 is perforated in therequired pattern to substantially coincide with the first to fifthmetatarsal heads and big toe of a person's foot.

The region 14 at the forepart 16 of the insole 12 is then underlayedwith the first pad 18 on the first face 34 of the insole 12. The firstpad 18 may be adhered to the insole 12, for example, with a pressuresensitive adhesive.

The cover 30 is then attached to the forepart 16 to encapsulate thefirst pad 18. The cover 30 may be attached using a suitable adhesive,e.g. a hot-melt adhesive.

An opening 20 is cut out from the insole 12 at the heel region 22. Theinsert 24 is then positioned in the opening 22.

The second pad 26 is positioned to underlie the insert 24 on the firstface 34 of the insole 12. The second pad 26 is attached to the insert 24and the surrounding portion of the insole 12 by a suitable adhesive,e.g. a hot-melt adhesive.

A shank support 32 may be attached to the insole 12. The shank support12 is attached on the first face 34 of the insole 12. Again, a suitableadhesive or other means of attachment may be used.

Having completed manufacture of the cushioning device 10 as hereinabovedescribed, the cushioning device 10 may then be used in the manufactureof an item of footwear 100.

An item of footwear 100 may be made by providing a footwear upper 102.The footwear upper 102 is positioned over the cushioning device 10.

The second face 36 of the insole 12 is provided to face the interior ofthe item of footwear 100.

The footwear upper 102 has a lasting margin 104 which surrounds theperiphery of the cushioning device 10.

An outsole 106 is then attached to the footwear upper 102, thecushioning device 10 and the lasting margin 104 such that the outsole106 covers the first and second pads 18 and 26, the cover 30, 'shanksupport 32 and the first face 34 of the insole 12.

A material, e.g. polyurethane, may be injected and bonded to the lastingmargin 104 of the footwear upper 102 and the cushioning device 10 toform the outsole 106 as can be seen in FIGS. 6-9. The surface of thesecond pad 26 may be scoured to enhance the bonding of the outsolematerial thereto.

The first and second pads 18 and 26, the cover 30 and the shank support32 are embedded in the outsole 106 of the footwear 100.

The innersock 103 may be loose and simply inserted into the item offootwear 100 to overlie the second face 36 of the insole 12.Alternatively, the innersock 103 may be adhered to the second face 36 ofthe insole 12 prior positioning the footwear upper 102 over thecushioning device 10.

The outsole 106 may be attached to the footwear upper 102, thecushioning device 10 and the lasting margin 104 in a manner similar tothe attachment of an outsole to the insole and lasting margin in knownfootwear.

The cushioning device 10 of the present invention when incorporated infootwear 100 provides energy absorption to the wearer which reduces therisk of injury caused by high and peak pressures acting on the foot dueto impact shock and stress forces. The cushioning device 10 providesenergy absorption to the areas of the foot which are most susceptible tohigh and peak pressures due to impact shock and stress forces. Theseareas of the foot are at the heel region and forepart of the foot.

Shock and energy absorption refer to the ability to absorb compressionloads and impact forces.

The provision of an insert 24 in the cutout opening 20 and theunderlying second pad 26 enables transfer of impact energy from the footto the energy absorbing material of the insert 24 and the second pad 26.The region 14 at the forepart 16 of the insole 12 allows the insole 12to contour to the shape of the first to fifth metatarsal heads and thelarge toe and also enables transfer of impact energy, or impact force,from the foot to the first pad 18. In particular, providing the region14 by way of perforations 28 gives flexibility to the region 14 of theinsole 12 and is responsive in transferring impact energy, or impactforce, from the area of contact, of the outsole 106 with the ground, tothe first pad 18. In addition, the perforations 28 reduce the rigidityof the region 14 of the insole 12 and enable the region 14 to conform tothe compression which is imparted by the wearer's foot to the insole 12.The perforations 28 provide flexibility at the region 14 but enable theregion 14 of the insole 12 to still provide support under the first tofifth metatarsal heads and the big toe of a wearer's foot which isimportant for enabling the foot to maintain balance.

Footwear 100 incorporating a cushioning device 10 also provides improvedflexibility and comfort to the wearer.

Footwear 100 incorporating the cushioning device 10 of the presentinvention, having an insert 24 in the heel region 22 and first andsecond pads 18 and 26 on the under-face of the insole 12, embedded inthe outsole 106, provides shock absorption from impact from bothdirections. That is, firstly, it provides shock absorption from impactcaused by the wearer's foot—this is impact in the downward direction.Secondly, it provides shock absorption from impacts with the outsole106, e.g. when the outsole 106 contacts irregularities in the surfaceupon which the wearer is walking,—these impacts are in the upwarddirection.

Modifications and variations such as would be apparent to a skilledaddressee are deemed to be within the scope of the present invention.

Throughout the specification, unless the context requires otherwise, theword “comprise” or variations such as “comprises” or “comprises”, willbe understood to imply the inclusion of a stated integer or group ofintegers but not the exclusion of any other integer or group ofintegers.

What is claimed is:
 1. Cushioning device for footwear comprising aninsole; a region at the forepart of said insole having perforations suchthat said region at the forepart of said insole has greater flexibilitythan the remainder of said insole to enable said region at the forepartof said insole to conform in response to compression imparted to saidinsole; first pad means on the under-face of said insole underlying saidregion at the forepart of said insole, said first pad is ofsubstantially the same shape and size as said region at the forepart ofsaid insole; a cutout opening in the heel region of said insole; aninsert provided in said cutout opening; second pad on the under-face ofsaid insole underlying said insert and said first and second pad andsaid insert being substantially shock absorbing and resilient. 2.Cushioning device according to claim 1, wherein said region at theforepart of said insole substantially coincides with the first to fifthmetatarsal heads and big toe of a person's foot.
 3. Cushioning deviceaccording to claim 1, wherein a cover is provided over said first pad onthe under-face of said insole at said forepart of said insole. 4.Cushioning device according to claim 1, wherein said first pad isattached to said insole.
 5. Cushioning device according to claim 1,wherein said second pad is attached to said insole and said insert. 6.Cushioning device according to claim 1, wherein a shank support isprovided at substantially the mid region of said insole intermediatesaid forepart and said heel region thereof.
 7. Cushioning deviceaccording to claim 6, wherein said shank support does not overlap withsaid first or second pad.
 8. Cushioning device according to claim 6,wherein said shank support is substantially in the form of a strip ofsupportive material having greater rigidity than said insole. 9.Cushioning device according to claim 6, wherein said shank support isprovided on said under-face of said insole.
 10. Cushioning deviceaccording to claim 1, wherein said perforations at said region at theforepart of said insole have a diameter substantially in the range of 1mm-2 mm.
 11. Cushioning device according to claim 1, wherein said secondpad is larger than said insert such that said second pad covers saidinsert and overlaps onto the surrounding portion of said insole. 12.Cushioning device according to claim 1, wherein said insole is a singlepiece of material.
 13. Cushioning device according to claim 1, whereinsaid insole is made of non-woven textile material or fibreboard.
 14. Anitem of footwear comprising a footwear upper, a cushioning deviceaccording to claim 1, and an outsole attached to said footwear upper,wherein said outsole covers said first and second pads and saidunder-face of said insole.
 15. An item of footwear according to claim14, wherein said footwear upper is provided with a lasting margin whichsubstantially surrounds the periphery of said cushioning device and isattached to said cushioning device.
 16. A method of making an item offootwear comprising providing a footwear upper, providing a cushioningdevice according to claim 1, covering said first and second pad and saidunder-face of said insole with an outsole, and attaching said outsole tosaid footwear upper.
 17. A method of making a cushioning device forfootwear comprising; providing an insole; perforating a region at theforepart of said insole such that said region at the forepart of saidinsole has greater flexibility than the remainder of said insole toenable said region at the forepart of said insole to conform in responseto compression imparted to said insole; underlying said region at theforepart of said insole with a first pad on the under-face of saidinsole, said first pad being substantially the same shape and size assaid region at the forepart of said insole; cutting out an opening inthe heel region of said insole; positioning an insert in said opening;underlying said insert with a second pad on the under-face of saidinsole; and said first and second pad and said insert beingsubstantially shock absorbing and resilient.
 18. A method according toclaim 17, wherein it further comprises providing said region at theforepart of said insole to substantially coincide with the first tofifth metatarsal heads and big toe of a person's foot.
 19. A methodaccording to claim 17, wherein it further comprises covering said firstpad at the forepart of said insole on the under-face of said insole. 20.A method according to claim 17, wherein it further comprises attachingsaid first pad to said insole.
 21. A method according to claim 17,wherein it further comprises attaching said second pad to said insoleand said insert.
 22. A method according to claim 17, wherein it furthercomprises providing a shank support substantially at the mid region ofsaid insole intermediate said forepart and said heel region thereof. 23.A method according to claim 22, wherein it further comprises providingsaid shank support on the under-face of said insole.
 24. A method ofmaking an item of footwear comprising providing a footwear upper, makinga cushioning device according to claim 17, covering said first andsecond pad and said under-face of said insole with an outsole, andattaching said outsole to said footwear upper.
 25. A method according toclaim 24, wherein it further comprises attaching a lasting margin tosaid cushioning device, said footwear upper provided with said lastingmargin which substantially surrounds the periphery of said cushioningdevice.
 26. A method according to claim 24, wherein it further comprisesoverlying said insole with an innersock.
 27. A method according to claim16, wherein it further comprises attaching a lasting margin to saidcushioning device, said footwear upper provided with said lasting marginwhich substantially surrounds the periphery of said cushioning device.28. A method according to claim 16, wherein it further comprisesoverlying said insole with an innersock.